Method of expansion

ABSTRACT

A method of expansion.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S.provisional patent application Ser. No. 60/600,679, attorney docketnumber 25791.194, filed on Aug. 11, 2004, the disclosure which isincorporated herein by reference.

This application is a continuation-in-part of one or more of thefollowing: (1) PCT application US02/04,353, filed on Feb. 14, 2002,attorney docket no. 25791.50.02, which claims priority from U.S.provisional patent application Ser. No. 60/270,007, attorney docket no.25791.50, filed on Feb. 20, 2001; (2) PCT application US 03/00,609,filed on Jan. 9, 2003, attorney docket no. 25791.71.02, which claimspriority from U.S. provisional patent application Ser. No. 60/357,372,attorney docket no. 25791.71, filed on Feb. 15, 2002; and (3) U.S.provisional patent application Ser. No. 60/585,370, attorney docketnumber 25791.299, filed on Jul. 2, 2004, the disclosures of which areincorporated herein by reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3,1999, which claims priority from provisional application 60/111,293,filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimspriority from provisional application 60/121,702, filed on Feb. 25,1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docketno. 25791.8.02, filed on Feb. 10, 2000, which claims priority fromprovisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S.Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No.09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorneydocket no. 25791.10.04, filed on 7/1/02, which claims priority fromprovisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S.patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02,filed on Mar. 10, 2000, which claims priority from provisionalapplication 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No.6,568,471, which was filed as patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimspriority from provisional application 60/121,841, filed on Feb. 26,1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent applicationSer. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24,2000, which claims priority from provisional application 60/121,907,filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed aspatent application Ser. 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BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a method of forming atubular liner within a preexisting structure is provided that includespositioning a tubular assembly within the preexisting structure; andradially expanding and plastically deforming the tubular assembly withinthe preexisting structure, wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe tubular assembly has a lower yield point than another portion of thetubular assembly.

According to another aspect of the present invention, a method ofradially expanding and plastically deforming a tubular assemblyincluding a first tubular member coupled to a second tubular member isprovided that includes radially expanding and plastically deforming thetubular assembly within a preexisting structure; and using less power toradially expand each unit length of the first tubular member than toradially expand each unit length of the second tubular member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 2 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 1 after positioning an expansion device within theexpandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 2 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 3 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 5 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 1-4.

FIG. 6 is a graphical illustration of the an exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 1-4.

FIG. 7 is a fragmentary cross sectional illustration of an embodiment ofa series of overlapping expandable tubular members.

FIG. 8 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 9 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 8 after positioning an expansion device within theexpandable tubular member.

FIG. 10 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 9 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 11 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 10 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 12 is a graphical illustration of exemplary embodiments of thestress/strain curves for several portions of the expandable tubularmember of FIGS. 8-11.

FIG. 13 is a graphical illustration of an exemplary embodiment of theyield strength vs. ductility curve for at least a portion of theexpandable tubular member of FIGS. 8-11.

FIG. 14 is a fragmentary cross sectional view of an exemplary embodimentof an expandable tubular member positioned within a preexistingstructure.

FIG. 15 is a fragmentary cross sectional view of the expandable tubularmember of FIG. 14 after positioning an expansion device within theexpandable tubular member.

FIG. 16 is a fragmentary cross sectional view of the expandable tubularmember of Fig. 15 after operating the expansion device within theexpandable tubular member to radially expand and plastically deform aportion of the expandable tubular member.

FIG. 17 is a fragmentary cross sectional view of the expandable tubularmember of Fig. 16 after operating the expansion device within theexpandable tubular member to radially expand and plastically deformanother portion of the expandable tubular member.

FIG. 18 is a flow chart illustration of an exemplary embodiment of amethod of processing an expandable tubular member.

FIG. 19 is a graphical illustration of the an exemplary embodiment ofthe yield strength vs. ductility curve for at least a portion of theexpandable tubular member during the operation of the method of FIG. 18.

FIG. 20 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 21 is a graphical illustration of stress/strain curves for anexemplary embodiment of an expandable tubular member.

FIG. 35 a is a fragmentary cross-sectional illustration of an exemplaryembodiment of an expandable tubular member.

FIG. 35 b is a graphical illustration of an exemplary embodiment of thevariation in the yield point for the expandable tubular member of FIG.35 a.

FIG. 36 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 36 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 36 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 37 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 37 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 37 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

FIG. 38 a is a flow chart illustration of an exemplary embodiment of amethod for processing a tubular member.

FIG. 38 b is an illustration of the microstructure of an exemplaryembodiment of a tubular member prior to thermal processing.

FIG. 38 c is an illustration of the microstructure of an exemplaryembodiment of a tubular member after thermal processing.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring initially to FIG. 1, an exemplary embodiment of an expandabletubular assembly 10 includes a first expandable tubular member 12coupled to a second expandable tubular member 14. In several exemplaryembodiments, the ends of the first and second expandable tubularmembers, 12 and 14, are coupled using, for example, a conventionalmechanical coupling, a welded connection, a brazed connection, athreaded connection, and/or an interference fit connection. In anexemplary embodiment, the first expandable tubular member 12 has aplastic yield point YP₁, and the second expandable tubular member 14 hasa plastic yield point YP₂. In an exemplary embodiment, the expandabletubular assembly 10 is positioned within a preexisting structure suchas, for example, a wellbore 16 that traverses a subterranean formation18.

As illustrated in FIG. 2, an expansion device 20 may then be positionedwithin the second expandable tubular member 14. In several exemplaryembodiments, the expansion device 20 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 20 is positioned within thesecond expandable tubular member 14 before, during, or after theplacement of the expandable tubular assembly 10 within the preexistingstructure 16.

As illustrated in FIG. 3, the expansion device 20 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 14 to form a bell-shaped section.

As illustrated in FIG. 4, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 14 and at least a portion of the firstexpandable tubular member 12.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 12 and14, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 16.

In an exemplary embodiment, as illustrated in FIG. 5, the plastic yieldpoint YP₁ is greater than the plastic yield point YP₂. In this manner,in an exemplary embodiment, the amount of power and/or energy requiredto radially expand the second expandable tubular member 14 is less thanthe amount of power and/or energy required to radially expand the firstexpandable tubular member 12.

In an exemplary embodiment, as illustrated in FIG. 6, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

In an exemplary embodiment, as illustrated in FIG. 7, following thecompletion of the radial expansion and plastic deformation of theexpandable tubular assembly 10 described above with reference to FIGS.1-4, at least a portion of the second expandable tubular member 14 hasan inside diameter that is greater than at least the inside diameter ofthe first expandable tubular member 12. In this manner a bell-shapedsection is formed using at least a portion of the second expandabletubular member 14. Another expandable tubular assembly 22 that includesa first expandable tubular member 24 and a second expandable tubularmember 26 may then be positioned in overlapping relation to the firstexpandable tubular assembly 10 and radially expanded and plasticallydeformed using the methods described above with reference to FIGS. 1-4.Furthermore, following the completion of the radial expansion andplastic deformation of the expandable tubular assembly 20, in anexemplary embodiment, at least a portion of the second expandabletubular member 26 has an inside diameter that is greater than at leastthe inside diameter of the first expandable tubular member 24. In thismanner a bell-shaped section is formed using at least a portion of thesecond expandable tubular member 26. Furthermore, in this manner, amono-diameter tubular assembly is formed that defines an internalpassage 28 having a substantially constant cross-sectional area and/orinside diameter.

Referring to FIG. 8, an exemplary embodiment of an expandable tubularassembly 100 includes a first expandable tubular member 102 coupled to atubular coupling 104. The tubular coupling 104 is coupled to a tubularcoupling 106. The tubular coupling 106 is coupled to a second expandabletubular member 108. In several exemplary embodiments, the tubularcouplings, 104 and 106, provide a tubular coupling assembly for couplingthe first and second expandable tubular members, 102 and 108, togetherthat may include, for example, a conventional mechanical coupling, awelded connection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, the first andsecond expandable tubular members 12 have a plastic yield point YP₁, andthe tubular couplings, 104 and 106, have a plastic yield point YP₂. Inan exemplary embodiment, the expandable tubular assembly 100 ispositioned within a preexisting structure such as, for example, awellbore 110 that traverses a subterranean formation 112.

As illustrated in FIG. 9, an expansion device 114 may then be positionedwithin the second expandable tubular member 108. In several exemplaryembodiments, the expansion device 114 may include, for example, one ormore of the following conventional expansion devices: a) an expansioncone; b) a rotary expansion device; c) a hydroforming expansion device;d) an impulsive force expansion device; d) any one of the expansiondevices commercially available from, or disclosed in any of thepublished patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 114 is positioned within thesecond expandable tubular member 108 before, during, or after theplacement of the expandable tubular assembly 100 within the preexistingstructure 110.

As illustrated in FIG. 10, the expansion device 114 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 108 to form a bell-shaped section.

As illustrated in FIG. 11, the expansion device 114 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 108, the tubular couplings, 104 and106, and at least a portion of the first expandable tubular member 102.

In an exemplary embodiment, at least a portion of at least a portion ofat least one of the first and second expandable tubular members, 102 and108, are radially expanded into intimate contact with the interiorsurface of the preexisting structure 110.

In an exemplary embodiment, as illustrated in FIG. 12, the plastic yieldpoint YP₁ is less than the plastic yield point YP₂. In this manner, inan exemplary embodiment, the amount of power and/or energy required toradially expand each unit length of the first and second expandabletubular members, 102 and 108, is less than the amount of power and/orenergy required to radially expand each unit length of the tubularcouplings, 104 and 106.

In an exemplary embodiment, as illustrated in FIG. 13, the firstexpandable tubular member 12 and/or the second expandable tubular member14 have a ductility D_(PE) and a yield strength YS_(PE) prior to radialexpansion and plastic deformation, and a ductility D_(AE) and a yieldstrength YS_(AE) after radial expansion and plastic deformation. In anexemplary embodiment, D_(PE) is greater than D_(AE), and YS_(AE) isgreater than YS_(PE). In this manner, the first expandable tubularmember 12 and/or the second expandable tubular member 14 are transformedduring the radial expansion and plastic deformation process.Furthermore, in this manner, in an exemplary embodiment, the amount ofpower and/or energy required to radially expand each unit length of thefirst and/or second expandable tubular members, 12 and 14, is reduced.Furthermore, because the YS_(AE) is greater than YS_(PE), the collapsestrength of the first expandable tubular member 12 and/or the secondexpandable tubular member 14 is increased after the radial expansion andplastic deformation process.

Referring to FIG. 14, an exemplary embodiment of an expandable tubularassembly 200 includes a first expandable tubular member 202 coupled to asecond expandable tubular member 204 that defines radial openings 204 a,204 b, 204 c, and 204 d. In several exemplary embodiments, the ends ofthe first and second expandable tubular members, 202 and 204, arecoupled using, for example, a conventional mechanical coupling, a weldedconnection, a brazed connection, a threaded connection, and/or aninterference fit connection. In an exemplary embodiment, one or more ofthe radial openings, 204 a, 204 b, 204 c, and 204 d, have circular,oval, square, and/or irregular cross sections and/or include portionsthat extend to and interrupt either end of the second expandable tubularmember 204. In an exemplary embodiment, the expandable tubular assembly200 is positioned within a preexisting structure such as, for example, awellbore 206 that traverses a subterranean formation 208.

As illustrated in FIG. 15, an expansion device 210 may then bepositioned within the second expandable tubular member 204. In severalexemplary embodiments, the expansion device 210 may include, forexample, one or more of the following conventional expansion devices: a)an expansion cone; b) a rotary expansion device; c) a hydroformingexpansion device; d) an impulsive force expansion device; d) any one ofthe expansion devices commercially available from, or disclosed in anyof the published patent applications or issued patents, of WeatherfordInternational, Baker Hughes, Halliburton Energy Services, Shell Oil Co.,Schlumberger, and/or Enventure Global Technology L.L.C. In severalexemplary embodiments, the expansion device 210 is positioned within thesecond expandable tubular member 204 before, during, or after theplacement of the expandable tubular assembly 200 within the preexistingstructure 206.

As illustrated in FIG. 16, the expansion device 210 may then be operatedto radially expand and plastically deform at least a portion of thesecond expandable tubular member 204 to form a bell-shaped section.

As illustrated in FIG. 16, the expansion device 20 may then be operatedto radially expand and plastically deform the remaining portion of thesecond expandable tubular member 204 and at least a portion of the firstexpandable tubular member 202.

In an exemplary embodiment, the anisotropy ratio AR for the first andsecond expandable tubular members is defined by the following equation:

AR=ln (WT_(f)/WT_(o))/ln (D_(f)/D_(o));

where AR=anisotropy ratio;

where WT_(f)=final wall thickness of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member;

where WT_(i)=initial wall thickness of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member;

where D_(f)=final inside diameter of the expandable tubular memberfollowing the radial expansion and plastic deformation of the expandabletubular member; and

where D_(i)=initial inside diameter of the expandable tubular memberprior to the radial expansion and plastic deformation of the expandabletubular member.

In an exemplary embodiment, the anisotropy ratio AR for the first and/orsecond expandable tubular members, 204 and 204, is greater than 1.

In an exemplary experimental embodiment, the second expandable tubularmember 204 had an anisotropy ratio AR greater than 1, and the radialexpansion and plastic deformation of the second expandable tubularmember did not result in any of the openings, 204 a, 204 b, 204 c, and204 d, splitting or otherwise fracturing the remaining portions of thesecond expandable tubular member. This was an unexpected result.

Referring to FIG. 18, in an exemplary embodiment, one or more of theexpandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202and/or 204 are processed using a method 300 in which a tubular member inan initial state is thermo-mechanically processed in step 302. In anexemplary embodiment, the thermo-mechanical processing 302 includes oneor more heat treating and/or mechanical forming processes. As a result,of the thermo-mechanical processing 302, the tubular member istransformed to an intermediate state. The tubular member is then furtherthermo-mechanically processed in step 304. In an exemplary embodiment,the thermo-mechanical processing 304 includes one or more heat treatingand/or mechanical forming processes. As a result, of thethermo-mechanical processing 304, the tubular member is transformed to afinal state.

In an exemplary embodiment, as illustrated in FIG. 19, during theoperation of the method 300, the tubular member has a ductility D_(PE)and a yield strength YS_(PE) prior to the final thermo-mechanicalprocessing in step 304, and a ductility D_(AE) and a yield strengthYS_(AE) after final thermo-mechanical processing. In an exemplaryembodiment, D_(PE) is greater than D_(AE), and YS_(AE) is greater thanYS_(PE). In this manner, the amount of energy and/or power required totransform the tubular member, using mechanical forming processes, duringthe final thermo-mechanical processing in step 304 is reduced.Furthermore, in this manner, because the YS_(AE) is greater thanYS_(PE), the collapse strength of the tubular member is increased afterthe final thermo-mechanical processing in step 304.

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have thefollowing characteristics:

Characteristic Value Tensile Strength 60 to 120 ksi Yield Strength 50 to100 ksi Y/T Ratio Maximum of 50/85% Elongation During Radial Expansionand Minimum of 35% Plastic Deformation Width Reduction During RadialExpansion Minimum of 40% and Plastic Deformation Wall ThicknessReduction During Radial Minimum of 30% Expansion and Plastic DeformationAnisotropy Minimum of 1.5 Minimum Absorbed Energy at −4 F. (−20 C.) in80 ft-lb the Longitudinal Direction Minimum Absorbed Energy at −4 F.(−20 C.) in 60 ft-lb the Transverse Direction Minimum Absorbed Energy at−4 F. (−20 C.) 60 ft-lb Transverse To A Weld Area Flare ExpansionTesting Minimum of 75% Without A Failure Increase in Yield Strength DueTo Radial Greater than 5.4% Expansion and Plastic Deformation

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, arecharacterized by an expandability coefficient f:

-   -   i. f=r×n    -   ii. where f=expandability coefficient;        -   1. r=anisotropy coefficient; and        -   2. n=strain hardening exponent.

In an exemplary embodiment, the anisotropy coefficient for one or moreof the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108,202 and/or 204 is greater than 1. In an exemplary embodiment, the strainhardening exponent for one or more of the expandable tubular members,12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.In an exemplary embodiment, the expandability coefficient for one ormore of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,108, 202 and/or 204 is greater than 0.12.

In an exemplary embodiment, a tubular member having a higherexpandability coefficient requires less power and/or energy to radiallyexpand and plastically deform each unit length than a tubular memberhaving a lower expandability coefficient. In an exemplary embodiment, atubular member having a higher expandability coefficient requires lesspower and/or energy per unit length to radially expand and plasticallydeform than a tubular member having a lower expandability coefficient.

In several exemplary experimental embodiments, one or more of theexpandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202and/or 204, are steel alloys having one of the following compositions:

Steel Element and Percentage By Weight Alloy C Mn P S Si Cu Ni Cr A0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02 B 0.18 1.28 0.017 0.004 0.290.01 0.01 0.03 C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05 D 0.02 1.310.02 0.001 0.45 — 9.1 18.7

In exemplary experimental embodiment, as illustrated in FIG. 20, asample of an expandable tubular member composed of Alloy A exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16)%, and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24)%. In an exemplary experimentalembodiment, YP_(AE24)%>YP_(AE16)%>YP_(BE). Furthermore, in an exemplaryexperimental embodiment, the ductility of the sample of the expandabletubular member composed of Alloy A also exhibited a higher ductilityprior to radial expansion and plastic deformation than after radialexpansion and plastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy A exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation:

Width Wall Yield Elon- Reduc- Thickness Point Yield gation tionReduction Aniso- ksi Ratio % % % tropy Before 46.9 0.69 53 −52 55 0.93Radial Expansion and Plastic Deformation After 16% 65.9 0.83 17 42 510.78 Radial Expansion After 24% 68.5 0.83 5 44 54 0.76 Radial Expansion% Increase 40% for 16% radial expansion 46% for 24% radial expansion

In exemplary experimental embodiment, as illustrated in FIG. 21, asample of an expandable tubular member composed of Alloy B exhibited ayield point before radial expansion and plastic deformation YP_(BE), ayield point after radial expansion and plastic deformation of about 16%YP_(AE16)%, and a yield point after radial expansion and plasticdeformation of about 24% YP_(AE24)%. In an exemplary embodiment,YP_(AE24)%>YP_(AE16)%>YP_(BE). Furthermore, in an exemplary experimentalembodiment, the ductility of the sample of the expandable tubular membercomposed of Alloy B also exhibited a higher ductility prior to radialexpansion and plastic deformation than after radial expansion andplastic deformation. These were unexpected results.

In an exemplary experimental embodiment, a sample of an expandabletubular member composed of Alloy B exhibited the following tensilecharacteristics before and after radial expansion and plasticdeformation:

Width Wall Yield Elon- Reduc- Thickness Point Yield gation tionReduction Aniso- ksi Ratio % % % tropy Before 57.8 0.71 44 43 46 0.93Radial Expansion and Plastic Deformation After 16% 74.4 0.84 16 38 420.87 Radial Expansion After 24% 79.8 0.86 20 36 42 0.81 Radial Expansion% Increase 28.7% increase for 16% radial expansion 38% increase for 24%radial expansion

In an exemplary experimental embodiment, samples of expandable tubularscomposed of Alloys A, B, C, and D exhibited the following tensilecharacteristics prior to radial expansion and plastic deformation:

Absorbed Steel Yield Yield Elongation Aniso- Energy Expandability Alloyksi Ratio % tropy ft-lb Coefficient A 47.6 0.71 44 1.48 145 B 57.8 0.7144 1.04 62.2 C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 —

In an exemplary embodiment, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have astrain hardening exponent greater than 0.12, and a yield ratio is lessthan 0.85.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having a carbon content (by weight percentage) less than orequal to 0.12%, is given by the following expression:

C_(e)=C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15

where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Mn=manganese percentage by weight;

c. Cr=chromium percentage by weight;

d. Mo=molybdenum percentage by weight;

e. V=vanadium percentage by weight;

f. Ti=titanium percentage by weight;

g. Nb=niobium percentage by weight;

h. Ni=nickel percentage by weight; and

i. Cu=copper percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having a carbon content less than or equal to 0.12% (byweight), for one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.

In an exemplary embodiment, the carbon equivalent C_(e), for tubularmembers having more than 0.12% carbon content (by weight), is given bythe following expression:

C_(e)=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B

where C_(e)=carbon equivalent value;

a. C=carbon percentage by weight;

b. Si=silicon percentage by weight;

c. Mn=manganese percentage by weight;

d. Cu=copper percentage by weight;

e. Cr=chromium percentage by weight;

f. Ni=nickel percentage by weight;

g. Mo=molybdenum percentage by weight;

h. V=vanadium percentage by weight; and

i. B=boron percentage by weight.

In an exemplary embodiment, the carbon equivalent value C_(e), fortubular members having greater than 0.12% carbon content (by weight),for one or more of the expandable tubular members, 12, 14, 24, 26,102,104, 106, 108, 202 and/or 204 is less than 0.36.

In several exemplary embodiments, the first and second tubular membersdescribed above with reference to FIGS. 1 to 21 are radially expandedand plastically deformed using the expansion device in a conventionalmanner and/or using one or more of the methods and apparatus disclosedin one or more of the following: The present application is related tothe following: (1) U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, attorney docket no. 25791.7.02, filedon Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460,attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941,attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patentapplication Ser. No. 09/588,946, attorney docket no. 25791.17.02, filedon Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122,attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patentapplication serial no. PCT/US00/18635, attorney docket no. 25791.25.02,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on No. 1, 1999, (12)U.S. provisional patent application Ser. No. 60/154,047, attorney docketno. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patentapplication Ser. No. 60/159,082, attorney docket no. 25791.34, filed onOct. 12, 1999, (14) U.S. provisional patent application Ser. No.60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15)U.S. provisional patent application Ser. No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, attorney docket no. 25791.38, filed onJun. 19, 2000, (17) U.S. provisional patent application Ser. No.60/165,228, attorney docket no. 25791.39, filed on No. 12, 1999, (18)U.S. provisional patent application Ser. No. 60/221,443, attorney docketno. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patentapplication Ser. No. 60/221,645, attorney docket no. 25791.46, filed onJul. 28, 2000, (20) U.S. provisional patent application Ser. No.60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (21)U.S. provisional patent application Ser. No. 60/237,334, attorney docketno. 25791.48, filed on Oct. 2, 2000, (22) U.S. provisional patentapplication Ser. No. 60/270,007, attorney docket no. 25791.50, filed onFeb. 20, 2001, (23) U.S. provisional patent application Ser. No.60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (24)U.S. provisional patent application Ser. No. 60/259,486, attorney docketno. 25791.52, filed on Jan. 3, 2001, (25) U.S. provisional patentapplication Ser. No. 60/303,740, attorney docket no. 25791.61, filed onJul. 6, 2001, (26) U.S. provisional patent application Ser. No.60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (27)U.S. provisional patent application Ser. No. 60/317,985, attorney docketno. 25791.67, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/3318,386, attorney docket no. 25791.67.02, filedon Sep. 10, 2001, (29) U.S. utility patent application Ser. No.09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (30)U.S. utility patent application Ser. No. 10/016,467, attorney docket no.25791.70, filed on Dec. 10, 2001, (31) U.S. provisional patentapplication Ser. No. 60/343,674, attorney docket no. 25791.68, filed onDec. 27, 2001; and (32) U.S. provisional patent application Ser. No.60/346,309, attorney docket no. 25791.92, filed on Jan. 7, 2002, thedisclosures of which are incorporated herein by reference.

Referring to FIG. 35 a an exemplary embodiment of an expandable tubularmember 3500 includes a first tubular region 3502 and a second tubularportion 3504. In an exemplary embodiment, the material properties of thefirst and second tubular regions, 3502 and 3504, are different. In anexemplary embodiment, the yield points of the first and second tubularregions, 3502 and 3504, are different. In an exemplary embodiment, theyield point of the first tubular region 3502 is less than the yieldpoint of the second tubular region 3504. In several exemplaryembodiments, one or more of the expandable tubular members, 12, 14, 24,26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member3500.

Referring to FIG. 35 b, in an exemplary embodiment, the yield pointwithin the first and second tubular regions, 3502 a and 3502 b, of theexpandable tubular member 3502 vary as a function of the radial positionwithin the expandable tubular member. In an exemplary embodiment, theyield point increases as a function of the radial position within theexpandable tubular member 3502. In an exemplary embodiment, therelationship between the yield point and the radial position within theexpandable tubular member 3502 is a linear relationship. In an exemplaryembodiment, the relationship between the yield point and the radialposition within the expandable tubular member 3502 is a non-linearrelationship. In an exemplary embodiment, the yield point increases atdifferent rates within the first and second tubular regions, 3502 a and3502 b, as a function of the radial position within the expandabletubular member 3502. In an exemplary embodiment, the functionalrelationship, and value, of the yield points within the first and secondtubular regions, 3502 a and 3502 b, of the expandable tubular member3502 are modified by the radial expansion and plastic deformation of theexpandable tubular member.

In several exemplary embodiments, one or more of the expandable tubularmembers, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, priorto a radial expansion and plastic deformation, include a microstructurethat is a combination of a hard phase, such as martensite, a soft phase,such as ferrite, and a transitionary phase, such as retained austentite.In this manner, the hard phase provides high strength, the soft phaseprovides ductility, and the transitionary phase transitions to a hardphase, such as martensite, during a radial expansion and plasticdeformation. Furthermore, in this manner, the yield point of the tubularmember increases as a result of the radial expansion and plasticdeformation. Further, in this manner, the tubular member is ductile,prior to the radial expansion and plastic deformation, therebyfacilitating the radial expansion and plastic deformation. In anexemplary embodiment, the composition of a dual-phase expandable tubularmember includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3%Si.

In an exemplary experimental embodiment, as illustrated in FIGS. 36 a-36c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3600, in which, in step 3602, an expandable tubular member 3602 ais provided that is a steel alloy having following material composition(by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3602 a provided in step 3602 has a yield strength of 45 ksi, and atensile strength of 69 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 36 b, instep 3602, the expandable tubular member 3602 a includes amicrostructure that includes martensite, pearlite, and V, Ni, and/or Ticarbides.

In an exemplary embodiment, the expandable tubular member 3602 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3604.

In an exemplary embodiment, the expandable tubular member 3602 a is thenquenched in water in step 3606.

In an exemplary experimental embodiment, as illustrated in FIG. 36 c,following the completion of step 3606, the expandable tubular member3602 a includes a microstructure that includes new ferrite, grainpearlite, martensite, and ferrite. In an exemplary experimentalembodiment, following the completion of step 3606, the expandabletubular member 3602 a has a yield strength of 67 ksi, and a tensilestrength of 95 ksi.

In an exemplary embodiment, the expandable tubular member 3602 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3602 a, the yield strength of the expandable tubularmember is about 95 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 37 a-37c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3700, in which, in step 3702, an expandable tubular member 3702 ais provided that is a steel alloy having following material composition(by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si,0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3702 a provided in step 3702 has a yield strength of 60 ksi, and atensile strength of 80 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 37 b, instep 3702, the expandable tubular member 3702 a includes amicrostructure that includes pearlite and pearlite striation.

In an exemplary embodiment, the expandable tubular member 3702 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3704.

In an exemplary embodiment, the expandable tubular member 3702 a is thenquenched in water in step 3706.

In an exemplary experimental embodiment, as illustrated in FIG. 37 c,following the completion of step 3706, the expandable tubular member3702 a includes a microstructure that includes ferrite, martensite, andbainite. In an exemplary experimental embodiment, following thecompletion of step 3706, the expandable tubular member 3702 a has ayield strength of 82 ksi, and a tensile strength of 130 ksi.

In an exemplary embodiment, the expandable tubular member 3702 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3702 a, the yield strength of the expandable tubularmember is about 130 ksi.

In an exemplary experimental embodiment, as illustrated in FIGS. 38 a-38c, one or more of the expandable tubular members, 12, 14, 24, 26, 102,104, 106, 108, 202, 204 and/or 3502 are processed in accordance with amethod 3800, in which, in step 3802, an expandable tubular member 3802 ais provided that is a steel alloy having following material composition(by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.In an exemplary experimental embodiment, the expandable tubular member3802 a provided in step 3802 has a yield strength of 56 ksi, and atensile strength of 75 ksi.

In an exemplary experimental embodiment, as illustrated in FIG. 38 b, instep 3802, the expandable tubular member 3802 a includes amicrostructure that includes grain pearlite, widmanstatten martensiteand carbides of V, Ni, and/or Ti.

In an exemplary embodiment, the expandable tubular member 3802 a is thenheated at a temperature of 790° C. for about 10 minutes in step 3804.

In an exemplary embodiment, the expandable tubular member 3802 a is thenquenched in water in step 3806.

In an exemplary experimental embodiment, as illustrated in FIG. 38 c,following the completion of step 3806, the expandable tubular member3802 a includes a microstructure that includes bainite, pearlite, andnew ferrite. In an exemplary experimental embodiment, following thecompletion of step 3806, the expandable tubular member 3802 a has ayield strength of 60 ksi, and a tensile strength of 97 ksi.

In an exemplary embodiment, the expandable tubular member 3802 a is thenradially expanded and plastically deformed using one or more of themethods and apparatus described above. In an exemplary embodiment,following the radial expansion and plastic deformation of the expandabletubular member 3802 a, the yield strength of the expandable tubularmember is about 97 ksi.

In several exemplary embodiments, the teachings of the presentdisclosure are combined with one or more of the teachings disclosed inFR 2 841626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, thedisclosure of which is incorporated herein by reference.

A method of forming a tubular liner within a preexisting structure hasbeen described that includes positioning a tubular assembly within thepreexisting structure; and radially expanding and plastically deformingthe tubular assembly within the preexisting structure, wherein, prior tothe radial expansion and plastic deformation of the tubular assembly, apredetermined portion of the tubular assembly has a lower yield pointthan another portion of the tubular assembly. In an exemplaryembodiment, the predetermined portion of the tubular assembly has ahigher ductility and a lower yield point prior to the radial expansionand plastic deformation than after the radial expansion and plasticdeformation. In an exemplary embodiment, the predetermined portion ofthe tubular assembly has a higher ductility prior to the radialexpansion and plastic deformation than after the radial expansion andplastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a lower yield point prior to theradial expansion and plastic deformation than after the radial expansionand plastic deformation. In an exemplary embodiment, the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than other portions of thetubular assembly. In an exemplary embodiment, the method furtherincludes positioning another tubular assembly within the preexistingstructure in overlapping relation to the tubular assembly; and radiallyexpanding and plastically deforming the other tubular assembly withinthe preexisting structure, wherein, prior to the radial expansion andplastic deformation of the tubular assembly, a predetermined portion ofthe other tubular assembly has a lower yield point than another portionof the other tubular assembly. In an exemplary embodiment, the insidediameter of the radially expanded and plastically deformed other portionof the tubular assembly is equal to the inside diameter of the radiallyexpanded and plastically deformed other portion of the other tubularassembly. In an exemplary embodiment, the predetermined portion of thetubular assembly includes an end portion of the tubular assembly. In anexemplary embodiment, the predetermined portion of the tubular assemblyincludes a plurality of predetermined portions of the tubular assembly.In an exemplary embodiment, the predetermined portion of the tubularassembly includes a plurality of spaced apart predetermined portions ofthe tubular assembly. In an exemplary embodiment, the other portion ofthe tubular assembly includes an end portion of the tubular assembly. Inan exemplary embodiment, the other portion of the tubular assemblyincludes a plurality of other portions of the tubular assembly. In anexemplary embodiment, the other portion of the tubular assembly includesa plurality of spaced apart other portions of the tubular assembly. Inan exemplary embodiment, the tubular assembly includes a plurality oftubular members coupled to one another by corresponding tubularcouplings. In an exemplary embodiment, the tubular couplings include thepredetermined portions of the tubular assembly; and wherein the tubularmembers comprise the other portion of the tubular assembly. In anexemplary embodiment, one or more of the tubular couplings include thepredetermined portions of the tubular assembly. In an exemplaryembodiment, one or more of the tubular members include the predeterminedportions of the tubular assembly. In an exemplary embodiment, thepredetermined portion of the tubular assembly defines one or moreopenings. In an exemplary embodiment, one or more of the openingsinclude slots. In an exemplary embodiment, the anisotropy for thepredetermined portion of the tubular assembly is greater than 1. In anexemplary embodiment, the anisotropy for the predetermined portion ofthe tubular assembly is greater than 1. In an exemplary embodiment, thestrain hardening exponent for the predetermined portion of the tubularassembly is greater than 0.12. In an exemplary embodiment, theanisotropy for the predetermined portion of the tubular assembly isgreater than 1; and the strain hardening exponent for the predeterminedportion of the tubular assembly is greater than 0.12. In an exemplaryembodiment, the predetermined portion of the tubular assembly is a firststeel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yieldpoint of the predetermined portion of the tubular assembly is at mostabout 46.9 ksi prior to the radial expansion and plastic deformation;and the yield point of the predetermined portion of the tubular assemblyis at least about 65.9 ksi after the radial expansion and plasticdeformation. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly after the radial expansionand plastic deformation is at least about 40% greater than the yieldpoint of the predetermined portion of the tubular assembly prior to theradial expansion and plastic deformation. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.48. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a second steel alloy including: 0.18% C, 1.28% Mn,0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In anexemplary embodiment, the yield point of the predetermined portion ofthe tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is about 1.04. In an exemplaryembodiment, the predetermined portion of the tubular assembly includes athird steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment,the anisotropy of the predetermined portion of the tubular assembly,prior to the radial expansion and plastic deformation, is about 1.92. Inan exemplary embodiment, the predetermined portion of the tubularassembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn,0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplaryembodiment, the anisotropy of the predetermined portion of the tubularassembly, prior to the radial expansion and plastic deformation, isabout 1.34. In an exemplary embodiment, the yield point of thepredetermined portion of the tubular assembly is at most about 46.9 ksiprior to the radial expansion and plastic deformation; and wherein theyield point of the predetermined portion of the tubular assembly is atleast about 65.9 ksi after the radial expansion and plastic deformation.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly after the radial expansion and plasticdeformation is at least about 40% greater than the yield point of thepredetermined portion of the tubular assembly prior to the radialexpansion and plastic deformation. In an exemplary embodiment, theanisotropy of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is at least about 1.48.In an exemplary embodiment, the yield point of the predetermined portionof the tubular assembly is at most about 57.8 ksi prior to the radialexpansion and plastic deformation; and the yield point of thepredetermined portion of the tubular assembly is at least about 74.4 ksiafter the radial expansion and plastic deformation. In an exemplaryembodiment, the yield point of the predetermined portion of the tubularassembly after the radial expansion and plastic deformation is at leastabout 28% greater than the yield point of the predetermined portion ofthe tubular assembly prior to the radial expansion and plasticdeformation. In an exemplary embodiment, the anisotropy of thepredetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.04. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,is at least about 1.92. In an exemplary embodiment, the anisotropy ofthe predetermined portion of the tubular assembly, prior to the radialexpansion and plastic deformation, is at least about 1.34. In anexemplary embodiment, the anisotropy of the predetermined portion of thetubular assembly, prior to the radial expansion and plastic deformation,ranges from about 1.04 to about 1.92. In an exemplary embodiment, theyield point of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, ranges from about 47.6ksi to about 61.7 ksi. In an exemplary embodiment, the expandabilitycoefficient of the predetermined portion of the tubular assembly, priorto the radial expansion and plastic deformation, is greater than 0.12.In an exemplary embodiment, the expandability coefficient of thepredetermined portion of the tubular assembly is greater than theexpandability coefficient of the other portion of the tubular assembly.In an exemplary embodiment, the tubular assembly includes a wellborecasing, a pipeline, or a structural support. In an exemplary embodiment,the carbon content of the predetermined portion of the tubular assemblyis less than or equal to 0.12 percent; and wherein the carbon equivalentvalue for the predetermined portion of the tubular assembly is less than0.21. In an exemplary embodiment, the carbon content of thepredetermined portion of the tubular assembly is greater than 0.12percent; and wherein the carbon equivalent value for the predeterminedportion of the tubular assembly is less than 0.36. In an exemplaryembodiment, a yield point of an inner tubular portion of at least aportion of the tubular assembly is less than a yield point of an outertubular portion of the portion of the tubular assembly. In an exemplaryembodiment, yield point of the inner tubular portion of the tubular bodyvaries as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in an linear fashion as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the inner tubular portion of the tubular body varies in annon-linear fashion as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the outertubular portion of the tubular body varies as a function of the radialposition within the tubular body. In an exemplary embodiment, the yieldpoint of the outer tubular portion of the tubular body varies in anlinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the outer tubularportion of the tubular body varies in an non-linear fashion as afunction of the radial position within the tubular body. In an exemplaryembodiment, the yield point of the inner tubular portion of the tubularbody varies as a function of the radial position within the tubularbody; and wherein the yield point of the outer tubular portion of thetubular body varies as a function of the radial position within thetubular body. In an exemplary embodiment, the yield point of the innertubular portion of the tubular body varies in a linear fashion as afunction of the radial position within the tubular body; and wherein theyield point of the outer tubular portion of the tubular body varies in alinear fashion as a function of the radial position within the tubularbody. In an exemplary embodiment, the yield point of the inner tubularportion of the tubular body varies in a linear fashion as a function ofthe radial position within the tubular body; and wherein the yield pointof the outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a linear fashionas a function of the radial position within the tubular body. In anexemplary embodiment, the yield point of the inner tubular portion ofthe tubular body varies in a non-linear fashion as a function of theradial position within the tubular body; and wherein the yield point ofthe outer tubular portion of the tubular body varies in a non-linearfashion as a function of the radial position within the tubular body. Inan exemplary embodiment, the rate of change of the yield point of theinner tubular portion of the tubular body is different than the rate ofchange of the yield point of the outer tubular portion of the tubularbody. In an exemplary embodiment, the rate of change of the yield pointof the inner tubular portion of the tubular body is different than therate of change of the yield point of the outer tubular portion of thetubular body. In an exemplary embodiment, prior to the radial expansionand plastic deformation, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure. In an exemplary embodiment, prior to the radialexpansion and plastic deformation, at least a portion of the tubularassembly comprises a microstructure comprising a transitional phasestructure. In an exemplary embodiment, the hard phase structurecomprises martensite. In an exemplary embodiment, the soft phasestructure comprises ferrite. In an exemplary embodiment, thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the hard phase structure comprises martensite;wherein the soft phase structure comprises ferrite; and wherein thetransitional phase structure comprises retained austentite. In anexemplary embodiment, the portion of the tubular assembly comprising amicrostructure comprising a hard phase structure and a soft phasestructure comprises, by weight percentage, about 0.1% C, about 1.2% Mn,and about 0.3% Si.

A method of radially expanding and plastically deforming a tubularassembly including a first tubular member coupled to a second tubularmember has been described that includes radially expanding andplastically deforming the tubular assembly within a preexistingstructure; and using less power to radially expand each unit length ofthe first tubular member than to radially expand each unit length of thesecond tubular member. In an exemplary embodiment, the tubular memberincludes a wellbore casing, a pipeline, or a structural support.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments. Inaddition, one or more of the elements and teachings of the variousillustrative embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various illustrative embodiments.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1-77. (canceled)
 78. A method of forming a tubular liner within apreexisting structure, comprising: positioning a tubular assembly withinthe preexisting structure; and radially expanding and plasticallydeforming the tubular assembly within the preexisting structure;wherein, prior to the radial expansion and plastic deformation of thetubular assembly, a predetermined portion of the tubular assembly has alower yield point than another portion of the tubular assembly.
 79. Themethod of claim 78, wherein the predetermined portion of the tubularassembly comprises one or more of the following: a higher ductility anda lower yield point prior to the radial expansion and plasticdeformation than after the radial expansion and plastic deformation; ahigher ductility prior to the radial expansion and plastic deformationthan after the radial expansion and plastic deformation; a lower yieldpoint prior to the radial expansion and plastic deformation than afterthe radial expansion and plastic deformation; an end portion of thetubular assembly; a plurality of predetermined portions of the tubularassembly; and a plurality of spaced apart predetermined portions of thetubular assembly.
 80. The method of claim 78, wherein the predeterminedportion of the tubular assembly has a larger inside diameter after theradial expansion and plastic deformation than other portions of thetubular assembly.
 81. The method of claim 80, further comprising:positioning another tubular assembly within the preexisting structure inoverlapping relation to the tubular assembly; and radially expanding andplastically deforming the other tubular assembly within the preexistingstructure; wherein, prior to the radial expansion and plasticdeformation of the tubular assembly, a predetermined portion of theother tubular assembly has a lower yield point than another portion ofthe other tubular assembly.
 82. The method of claim 81, wherein theinside diameter of the radially expanded and plastically deformed otherportion of the tubular assembly is equal to the inside diameter of theradially expanded and plastically deformed other portion of the othertubular assembly.
 83. The method of claim 78, wherein the other portionof the tubular assembly comprises one or more of the following: an endportion of the tubular assembly; a plurality of other portions of thetubular assembly; and a plurality of spaced apart other portions of thetubular assembly.
 84. The method of claim 78, wherein the tubularassembly comprises a plurality of tubular members coupled to one anotherby corresponding tubular couplings.
 85. The method of claim 84, whereinthe tubular couplings comprise the predetermined portions of the tubularassembly; and wherein the tubular members comprise the other portion ofthe tubular assembly.
 86. The method of claim 84, wherein one or more ofthe tubular couplings comprise the predetermined portions of the tubularassembly.
 87. The method of claim 84, wherein one or more of the tubularmembers comprise the predetermined portions of the tubular assembly. 88.The method of claim 78, wherein the predetermined portion of the tubularassembly defines one or more openings.
 89. The method of claim 88,wherein one or more of the openings comprise slots.
 90. The method ofclaim 88, wherein the predetermined portion of the tubular assemblycomprises one or more of the following: an anisotropy greater than 1; astrain hardening exponent greater than 0.12; and an anisotropy greaterthan 1 and a strain hardening exponent greater than 0.12.
 91. The methodof claim 78, wherein the predetermined portion of the tubular assemblycomprises one or more of the following: a first steel alloy comprising:0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and0.02% Cr; a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P,0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr; a third steelalloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16%Cu, 0.05% Ni, and 0.05% Cr; and a fourth steel alloy comprising: 0.02%C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
 92. Themethod of claim 91, wherein the predetermined portion of the tubularassembly comprises one or more of the following: a yield point of atmost about 46.9 ksi prior to the radial expansion and plasticdeformation and at least about 65.9 ksi after the radial expansion andplastic deformation; a yield point after the radial expansion andplastic deformation that is at least about 40% greater than the yieldpoint prior to the radial expansion and plastic deformation; ananisotropy of about 1.48 prior to the radial expansion and plasticdeformation; a yield point of at most about 57.8 ksi prior to the radialexpansion and plastic deformation and at least about 74.4 ksi after theradial expansion and plastic deformation; a yield point after the radialexpansion and plastic deformation that is at least about 28% greaterthan the yield point prior to the radial expansion and plasticdeformation; an anisotropy of about 1.04 prior to the radial expansionand plastic deformation; an anisotropy of about 1.92 prior to the radialexpansion and plastic deformation; and an anisotropy of about 1.34 priorto the radial expansion and plastic deformation.
 93. The method of claim78, wherein the predetermined portion of the tubular assembly comprisesone or more of the following: a yield point of at most about 46.9 ksiprior to the radial expansion and plastic deformation and at least about65.9 ksi after the radial expansion and plastic deformation; a yieldpoint after the radial expansion and plastic deformation that is atleast about 40% greater than the yield point prior to the radialexpansion and plastic deformation; an anisotropy of about 1.48 prior tothe radial expansion and plastic deformation; a yield point of at mostabout 57.8 ksi prior to the radial expansion and plastic deformation andat least about 74.4 ksi after the radial expansion and plasticdeformation; a yield point after the radial expansion and plasticdeformation that is at least about 28% greater than the yield pointprior to the radial expansion and plastic deformation; an anisotropy ofat least about 1.04 prior to the radial expansion and plasticdeformation; an anisotropy of at least about 1.92 prior to the radialexpansion and plastic deformation; an anisotropy of at least about 1.34prior to the radial expansion and plastic deformation; an anisotropyranging from about 1.04 to about 1.92 prior to the radial expansion andplastic deformation; a yield point ranging from about 47.6 ksi to about61.7 ksi prior to the radial expansion and plastic deformation; anexpandability coefficient of greater than 0.12 prior to the radialexpansion and plastic deformation; and an expandability coefficient thatis greater than the expandability coefficient of the other portion ofthe tubular assembly.
 94. The method of claim 78, wherein the tubularassembly comprises one or more of the following: a wellbore casing; apipeline; and a structural support.
 95. The method of claim 78, whereinthe predetermined portion of the tubular assembly comprises one or moreof the following: a combination comprising a carbon content of less thanor equal to 0.12 percent and a carbon equivalent value of less than0.21; and a combination comprising a carbon content of greater than 0.12percent and a carbon equivalent value of less than 0.36.
 96. The methodof claim 78, wherein a yield point of an inner tubular portion of atleast a portion of the tubular assembly is less than a yield point of anouter tubular portion of the portion of the tubular assembly.
 97. Themethod of claim 96, wherein the yield point of the inner tubular portionof the tubular body varies as a function of the radial position withinthe tubular body.
 98. The method of claim 97, wherein the yield point ofthe inner tubular portion of the tubular body varies in a fashioncomprising one of the following: a linear fashion as a function of theradial position within the tubular body; and a non-linear fashion as afunction of the radial position within the tubular body.
 99. The methodof claim 96, wherein the yield point of the outer tubular portion of thetubular body varies as a function of the radial position within thetubular body.
 100. The method of claim 99, wherein the yield point ofthe outer tubular portion of the tubular body varies in a fashioncomprising one of the following: a linear fashion as a function of theradial position within the tubular body; and a non-linear fashion as afunction of the radial position within the tubular body.
 101. The methodof claim 96, wherein the yield point of the inner tubular portion of thetubular body varies as a function of the radial position within thetubular body; and wherein the yield point of the outer tubular portionof the tubular body varies as a function of the radial position withinthe tubular body.
 102. The method of claim 101, wherein the yield pointof the inner tubular portion of the tubular body varies in a fashioncomprising one of the following: a linear fashion as a function of theradial position within the tubular body; and a non-linear fashion as afunction of the radial position within the tubular body; and wherein theyield point of the outer tubular portion of the tubular body varies in afashion comprising one of the following: a linear fashion as a functionof the radial position within the tubular body; and a non-linear fashionas a function of the radial position within the tubular body.
 103. Themethod of claim 101, wherein the rate of change of the yield point ofthe inner tubular portion of the tubular body is different than the rateof change of the yield point of the outer tubular portion of the tubularbody.
 104. The method of claim 78, wherein prior to the radial expansionand plastic deformation, at least a portion of the tubular assemblycomprises a microstructure comprising a hard phase structure and a softphase structure.
 105. The method of claim 104, wherein prior to theradial expansion and plastic deformation, at least a portion of thetubular assembly comprises a microstructure comprising a transitionalphase structure.
 106. The method of claim 104, wherein the hard phasestructure comprises martensite.
 107. The method of claim 104, whereinthe soft phase structure comprises ferrite.
 108. The method of claim104, wherein the transitional phase structure comprises retainedaustentite.
 109. The method of claim 104, wherein the hard phasestructure comprises martensite; wherein the soft phase structurecomprises ferrite; and wherein the transitional phase structurecomprises retained austentite.
 110. The method of claim 104, wherein theportion of the tubular assembly comprising a microstructure comprising ahard phase structure and a soft phase structure comprises, by weightpercentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
 111. Amethod of radially expanding and plastically deforming a tubularassembly comprising a first tubular member coupled to a second tubularmember, comprising: radially expanding and plastically deforming thetubular assembly within a preexisting structure; and using less power toradially expand each unit length of the first tubular member than toradially expand each unit length of the second tubular member.
 112. Themethod of claim 111, wherein the tubular member comprises one or more ofthe following: a wellbore casing; a pipeline; and a structural support.